Plastic-coated hand rails, guard rails, and the like

ABSTRACT

The present invention includes at least two spaced apart vertical rails and two spaced apart horizontal rails, which engage the vertical rails and are positioned above the lower ends of the vertical rails. Multiple slip-on or slip-in structural fittings engage the horizontal rails with the vertical rails and include a security mechanism that secures the rails to the fittings. A plastic coating covers and seals the vertical and horizontal rails and the structural fittings.

Reference to Related Applications

[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/815,628, filed Mar. 23,2001, which claims priority from provisional patent application Ser. No.60/191,704, filed Mar. 23,2000, and is a continuation-in-part of co-pending U.S. patent application Ser. No. 09/394,595, filed Sep. 13, 1999, now U.S. Pat. No. 6,283,457, which is a continuation-in-part of U.S. patent application Ser. No.08/870,101, filed Jun. 5, 1998, now, abandoned, the entire contents of all of which are incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention is directed to a knock-down hand rail system. More particularly, the present invention relates to a unique knock-down hand rail system for use both indoors and outdoors.

BACKGROUND OF THE INVENTION

[0003] The typical hand rail is formed of metal and susceptible to affects of weather or other environmental conditions causing the rail to rust and deteriorate. A disadvantage of these metal rails is that such rails require regular upkeep such as painting to prevent rust or complete replacement when the metal rusts away.

[0004] To overcome this, galvanized steel has been used to avoid rust and hopefully, eliminate regular upkeep. A disadvantage of galvanized steel is that the sheen is too bright and is distracting when used in environments such as auditoriums or stadiums.

[0005] A still further disadvantage of both the metal and galvanized steel hand rail systems is that their assembly is of a permanent nature. That is, once the rail structure is assembled, the rail is permanently fixed at that location in that configuration.

[0006] There is a need for fence or barrier assemblies to support a panel, such as a sheet of glass, perforated metal, or steel mesh. Such an assembly can be used to protect equipment, prevent personnel from falling through an opening or over a ledge, and to block passage of unwanted materials or objects. U.S. Pat. No. 6,138,993 to Mitchell, Jr. et al. shows a protection screen that includes a plurality of screen panels and is self-supporting. This screen has limited utility, lacks a heavy-duty steel support frame surrounding the panel, does not provide for interchange of panels, and does not have a sheathing or covering to protect a support frame. U.S. Pat. No.5,967,214 to Berretta discloses a barrier with a tubular frame and an extruded sheet-like element shaped into a closed loop that may be fitted over the tubular frame. This barrier also has limited utility, is not adjustably configurable, and lacks sheathing on the tubular members. The panels also are shrink-fit to the frame making interchangeability difficult. U.S. Pat. No. 5,967,089 to Alan discloses a lightweight, collapsible, hinged fencing structure that includes multiple rectangular panels that are hingedly interconnected. Each panel consists of a plastic tubular frame with a lightweight polymeric sheet supported by the frame. This structure again has a limited utility and is not flexibly configurable. The plastic frame also lacks the requisite strength for application where a steel frame is required. U.S. Pat. No. 4,841,967 to Hogg et al. discloses a glass panel mounting assembly that forms a glass barrier with a rail at the top edge. The glass panel forms a decorative barrier that lacks the requisite strengths for many applications. It is not flexibly configurable, and lacks a steel surrounding frame. In light of the above, there remains a need for a barrier assembly that is adjustably configurable, has steel frame members interconnected with one another, and a plastic sheathing over the rails, and may support a panel.

SUMMARY OF THE INVENTION

[0007] The present invention provides a hand rail system that is formed of preferably metal vertical and horizontal rails that are interconnected using structural slip-in or slip-on fittings. The entire assembly is coated with a plastic coating, such as spray-on polyurea, to cover and seal the rails and fittings. In some embodiments, the horizontal and vertical rails define a framed area and an infill panel is disposed in the framed area. The infill panel may be coated with a plastic coating along with the rails and fittings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is a perspective view of the hand rail assembly of the present invention;

[0009]FIG. 2 is an exploded view of a preferred embodiment of the hand rail assembly of the present invention;

[0010]FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 1;

[0011]FIG. 4 is a perspective view of a second preferred embodiment of the hand rail assembly of the present invention;

[0012]FIG. 5 illustrates, from an oblique perspective, an alternative embodiment of the invention including a mesh infill;

[0013]FIG. 6 is a close-up detail of the corner of the assembly of FIG. 5;

[0014]FIG. 7 illustrates an alternative way of forming U-channels according to the invention to ensure that there are no gaps in the infill;

[0015]FIG. 8 illustrates the use of clips as opposed to full-length channels, and an alternative corner gap-filling corner configuration;

[0016]FIG. 9 is a perspective view of another preferred embodiment of a barrier assembly with an infill panel according to the present invention;

[0017]FIG. 10 is an end view of the barrier assembly of FIG. 9;

[0018]FIG. 11 is a front elevational view of the barrier assembly of FIG. 9;

[0019]FIG. 12 is a top plan view of the barrier assembly of FIG. 9;

[0020]FIG. 13 is a bottom plan view of the barrier assembly of FIG. 9;

[0021]FIG. 14 is a perspective view of another embodiment of a barrier assembly with an infill panel according to the present invention, utilizing an alternative slip-in structural fitting;

[0022]FIG. 15 is an end view of the barrier assembly of FIG. 14;

[0023]FIG. 16 is a front elevational view of the barrier assembly of FIG. 14;

[0024]FIG. 17 is top plan view of the barrier assembly of FIG. 14;

[0025]FIG. 18 is a bottom plan view of the barrier assembly of FIG. 14;

[0026]FIG. 19 is a detailed end view of one embodiment of a clip for holding an infill panel for a barrier assembly according the present invention;

[0027]FIG. 20 is a detailed perspective view of a slip-in structural fitting interconnecting a horizontal and vertical rail;

[0028]FIG. 21 is a detailed perspective view of another slip-in structural fitting interconnecting a horizontal and vertical rail, along with an end cap closing the end of a horizontal rail;

[0029]FIG. 22 is an exploded perspective view of a portion of a horizontal and vertical rail along with a slip-in structural fitting; and

[0030]FIG. 23 is a detailed view of an alternative embodiment of a slip-in structural fitting.

DETAILED DESCRIPTION OF THE INVENTION

[0031] With reference to FIGS. 1 and 2, a knock down hand rail system 10 is thereshown. In this first preferred embodiment, at least two spaced apart vertical rails 12, 14 are provided and supported in an upright position by base supports 16, 18. These base supports 16, 18 provide removable and replaceable support with the ground 20 and are preferably secured to the ground 20 by bolts 22. Alternatively, the hand rail assembly can be cored to the ground for support.

[0032] The hand rail assembly of the present invention also includes at least two spaced apart horizontal rails 24, 26 removably engaged with vertical rails 12, 14 and positioned above base supports 16, 18.

[0033] As shown in FIG. 2, vertical rails 12, 14 are surrounded by removable and replaceable polymerized sheathing 28, 30. This sheathing 28, 30 preferably slip fits about vertical rails 12, 14 and has an interior diameter equal to or greater than the exterior diameter of vertical rails 12, 14. This aspect of the invention will be described in greater detail below.

[0034] As with vertical rails 12, 14, corresponding horizontal rails 24,26 are also surrounded by polymerized sheathing 32, 34 respectively. Additionally, this polymerized sheathing has an interior diameter that is equal to or greater than the exterior diameter of horizontal rails 24, 26. As stated above, this slip fit of the polymerized sheathing 32, 34 about horizontal rails 24, 26 will be described in detail later.

[0035] Slip-on structural fittings 36, 40 are provided to removably engage horizontal rails 24, 26 to each other and to vertical rails 12, 14. These slip-on structural fittings are preferably Hollaender structural fittings manufactured by The Hollaender Manufacturing Company, Cincinnati, Ohio. T-shaped slip-on structural fitting 36 may be provided to join horizontal rail 24 to horizontal rail 26 and include an extra opening for additional vertical rails if desired. T-shaped slip-on structural fitting 36 removably engages horizontal rails 24, 26 and polymerized sheathing 32, 34 by set screws 38.

[0036] L-shaped Hollaender slip-on structural fittings 40 removably engage horizontal rails 24, 26 to vertical rails 12, 14. L-shaped slip-on structural fittings 40 removably secure the rails to each other by set screws 42.

[0037] With reference to FIG. 3, each slip-on structural fitting provided to removably secure the knockdown hand rail system 10 of the present invention typically includes a structural fitting 40 for securing horizontal rail 24 with polymerized sheathing 32 to vertical rail 14 with polymerized sheathing 30. More specifically, interior diameter 44 of polymerized sheathing 32 is equal to or greater than exterior diameter 46 of horizontal rail 24. Additionally, interior diameter 48 of L-shaped slip-on fitting 40 is equal to or greater than the exterior diameter 50 of polymerized sheathing 32. Set screw 42 is preferably a counter bore knurled cup point set screw that securely fastens L-shape slip-on fitting 40 through polymerized sheathing 32 onto horizontal rail 24. This structural assembly is typical of all rails, polymerized sheathing, and slip-on fittings of the present invention.

[0038] In a second preferred embodiment of the present invention, a third vertical rail 52 may be provided therewith. Vertical rail 52 is also preferably surrounded by polymerized sheathing 54 having an interior diameter equal to or greater than the exterior diameter of vertical rail 52. Vertical rail 52 is typically provided with base support 56 for supporting vertical rail 52 in an upright position. Base support 56 may be secured to the ground 20 by bolts 22 as typically shown in base supports 16, 18.

[0039] Vertical rail 52 with polymerized sheathing 54 may be provided with a cross-shaped slip-on structural fitting 70 for supporting additional horizontal rails 58,60. These horizontal rails 58, 60 are also preferably surrounded by polymerized sheathing 62,64 respectively. As with all polymerized sheathing of the present invention, polymerized sheathing 62,64 has an interior diameter equal to or greater than the exterior diameter of horizontal rails 58, 60. Cross-shaped slip-on structural fitting 70 removably secures horizontal rails 58, 60 with polymerized sheathing 62, 64 to third vertical rail 52 with polymerized sheathing 54 by set screws 72. Horizontal rails 58, 60 with polymerized sheathing 62, 64 are secured to vertical rails 12, 14 with polymerized sheathing 28, 30 by T-shaped slip-on structural fittings 66 with set screws 68.

[0040] Proper assembly of the preferred present invention is as follows. Vertical rails 12, 14, 52 are spaced apart and supported in an upright position by base supports 16, 18, 56. These base supports are removably secured to the ground 20 by any mechanical means such as bolts 22. Removable and replaceable polymerized sheathing 28, 30, 54 is preferably slip-fit about corresponding vertical rails 12, 14, 52. T-shaped slip-on structural fittings 66 are slipped over polymerized sheathing 28, 30 to be secured and positioned later.

[0041] Horizontal rails 24, 26 are provided therewith and surrounded by corresponding polymerized sheathing 32, 34. One end of each horizontal rail is secured to L-shaped slip-on fitting 40 by a corresponding set screw 42. The opposite end of horizontal rails 24, 26 with corresponding polymerized sheathing 32, 34 is secured to a T-shaped slip-on fitting 36 by corresponding set screws 38. The entire removably secured structure of these horizontal rails is then placed atop corresponding vertical rails 12, 14, 52 with polymerized sheathing 28, 30, 54 respectively. Remaining set screws 38, 42 removably attach the horizontal rail structure to the vertical rail structure. Lastly, horizontal rails 58, 60 are surrounded by polymerized sheathing 62, 64 respectively. Each horizontal rail 58, 60 with corresponding polymerized sheathing 62, 64 are removably secured between vertical rails 12, 14, 52 with corresponding polymerized sheathing 28, 30, 54 by slip-on structural fittings 66, 70. Set screws 68, 72 removably engage these additional horizontal rails to the vertical rails at any point along the vertical rails.

[0042] An alternative embodiment of the present invention involves extension and bending of vertical rails 28, 30 to form horizontal rail 34, as shown in FIG. 4. That is, inner frame vertical rail 12, 14 is slip-fit into corresponding polymerized sheathing 28, 30 and is then bent to create a rounded corner and thereby extend into a horizontal rail. In this way, Hollaender fittings 40 would be eliminated and horizontal rails 24, 26 with corresponding polymerized sheathing 32, 34 would be replaced by extended vertical rails 12, 14 with polymerized sheathing 28, 30 to meet at Hollaender fittings 36. In an extended version of this preferred embodiment, Hollaender fitting 36 may be provided to simply support vertical rail 52 with polymerized sheathing 54 to the singularly extended vertical rail 12 with corresponding sheathing 28. In this embodiment, vertical rail 12 would then extend to form both exterior vertical rails 12, 14 and horizontal rails 24,26. A singular unit of polymerized sheathing would also extend about the singular rail and be bent to form rounded corners at the upper edges.

[0043] Alternative embodiments of the present invention may involve the use of only one top horizontal rail or several horizontal and vertical rails extending to create an elongated hand rail assembly 10. It was envisioned that each vertical rail will be removably supported to the ground by a base or structure if necessary. Additional base structures are also shown in FIG. 4. Moreover, each additional horizontal rail is preferably supported to the vertical rails by Hollaender slip-on structural fittings conforming to any shape necessary to create the overall structural shape of the hand rail assembly of the present invention. That is, the hand rail of the present invention may extend linearly, triangularly, circularly, or any other shape that may reasonably be configured. Moreover, each rail, vertical and horizontal, shall preferably be surrounded by polymerized sheathing having an interior diameter that is equal to or greater than the exterior diameter of the corresponding rail.

[0044]FIG. 5 illustrates, from a perspective view, an alternative embodiment of the invention generally at 102 including an infill disposed between the horizontal and vertical sheathing-covered rails 30 and 34. Although the embodiment depicted in FIGS. 5 and 6 illustrate the use of a mesh panel 106 received by continuous channels 104, it is readily apparent that the arrangement is conducive to the use of other types of infills, including clear and opaque plastics, glass, and meshes and perforated sheets having apertures of any scale, depending upon the application.

[0045]FIG. 6 is a close-up view of the way in which the channels 104 attach to the rails 30 and 34, and the way in which infill 106 is received thereby. Preferably, a plurality of spaced-apart self-tapping fasteners 105 are used to adhere the U-channels 104 to the members as shown. Since the fasteners 105 must go through the U-channel material, sheathing and wall of the associated rail, it may be advisable to predrill holes for each fastener, as the case may be. Although the material used for the infill may not include a finished edge, particularly when mesh panels are used, it is preferable to have a peripheral seam 108 to provide a more finished look. In terms of materials, the U-channels 104 are preferably constructed of some type of corrosion-resistant metal such as aluminum, though other types of metals and even non-metals may be used, so long as they are of sufficient strength and durability.

[0046] To fill the triangular gap which would otherwise be left due to the difference in height between the sheath covered rails and corner/T-assemblies 40 and 46, a configuration such as that depicted in FIG. 7 may alternatively be utilized. In this case, the U-channels 112 include relieved areas 114 such that, when assembled, a cleaner full comer appearance is achieved. In such a case, an infill having a square corner may be used, such as mesh screen 120 having a finished squared-off corner 122.

[0047]FIG. 8 illustrates certain additional alternative configurations according to the invention, which may be used independently or in combination with other arrangements described herein. For example, in place of a continuous U-channel, clips 140 may alternatively be used, particularly if the edge of the infill is peripherally finished or otherwise continuous. As a further option, the edge of the infill may be scalloped, as shown at 150. With such a shaped configuration, which may be used with clips or a continuous U-channel, the triangularly shaped gap shown in FIGS. 5 and 6 would be filled without having to grind or otherwise modify the U-channel or clip members.

[0048] Referring now to FIG. 9-13, an additional embodiment of a knock down hand rail system according to the present invention is generally shown at 200. The hand rail system has a pair of spaced apart vertical rails 202 and 204, each covered with a polymerized sheathing, as previously described. An upper rail 206 extends horizontally between the upper ends of the vertical posts 202 and 204 and is also covered with a removable and replaceable polymerized sheathing. Slip-on structural fittings 208 and 210 interconnect the ends of the upper rail 206 with the upper ends of the vertical posts 202 and 204, respectively. A lower rail 212 extends horizontally between the vertical posts 202 and 204 and is covered with a polymerized sheathing. It is interconnected at its ends with the vertical posts 202 and 204 using T-shaped slip-on structural fittings 214 and 216, respectively. The T-shaped fittings 214 and 216 may be moved upwardly and downwardly so as to change the spacing between the lower rail 212 and the upper rail 206. Though not shown, the structural fittings 208, 210, 214, 216 preferably includes screws or bolts that allow the fittings to grip the vertical and horizontal rails to which they connect. Preferably, the screws or bolts do not penetrate the polymerized sheathing or the rails or posts.

[0049] The vertical posts 202 and 204 and the upper and lower rails 206 and 212 together define a perimeter frame with a framed area 218 defined therein. The framed area has a top edge defined by the upper rail 206, a lower edge defined by the lower rail 212, and sides defined by the vertical post 202 and 204. An infill member or panel 220 is supported in the framed area. As previously discussed, the infill member or panel 220 may be any of a variety of materials including a glass, polymer, or perforated steel or plastic sheet, or a steel or fiberglass mesh. In the embodiment illustrated in FIG. 9, the panel 220 is a piece of steel or plastic with perforations. The panel 220 is supported in the framed area by a variety of clips 222. Each clip 222 grips an edge of the panel 220 and interconnects with one of the posts or rails. The illustrated infill panel 220 may be eliminated in some applications, with the vertical posts and horizontal rails acting as a hand rail.

[0050] In the illustrated embodiment, the lower ends of the vertical posts 202 and 204 extend downwardly below the underside of the lower rail 212. This design is configured so that the lower ends of the vertical post 202 and 204 fit into holes in a support surface. Alternatively, support members may be attached to the lower ends of the vertical posts 202 and 204.

[0051] Referring now to FIGS. 14-18, another embodiment of a knock down hand rail system with an infill panel according to the present invention is generally shown at 230. The hand rail system 230 is similar to the previous embodiments, and includes a pair of vertical posts 232 and 234, an upper rail 236 extending between the upper ends of the vertical post 232 and 234, and a lower rail 238 positioned below the upper rail 236 and also extending between the vertical posts 232 and 234. This embodiment differs from the prior embodiment in that the infill panel 240 is a sheet of glass or plastic, support members 242 and 245 engage the lower ends of the vertical post 232 and 234, respectively, and, most importantly, a different type of structural fitting is used to interconnect the rails and posts.

[0052] As with the previous embodiment, clips 246 interconnect the infill panel 240 with the rails and posts. FIG. 19 shows an end view of a clip 246. A clip 246 in FIG. 19 is oriented as are the clips that interconnect the infill panel with the upper rail 236 in FIG. 14. In this orientation, the clip 246 has an upper end 248 that is radiused so as to mate with the outer radius of the polymerized sheathing surrounding the upper rail 236. A bolt or screw, not shown passes through a bore 250 in the upper end and engages the upper rail 236. The lower end 252 of the clip has a slot-like opening 254 that accepts the edge of the infill panel 240. The width of the slot 254 depends on the thickness of the panel 240. Alternatively, the clip may be made adjustable to accommodate variations in thickness of infill panels, or the slot 254 may be lined to improve the engagement between the clip and panel. For example, a glass panel may require a rubberized lining in the clips to avoid chipping the edges of the glass.

[0053] Referring now to FIGS. 20-23, the alternative structural fitting used with the hand rail system of FIGS. 14-18 will be described in more detail. FIG. 20 is a detailed view of one of the lower corners of the hand rail system of FIG. 14 showing the support member 242 supporting the lower end of vertical post 232 which extends upwardly from the support member 242. The horizontal lower rail 238 is interconnected with the vertical post 232 just above the support member 242 using a structural fitting 260. The structural fitting 260 differs from the previous slip-on structural fitting in that it is a much more flush design.

[0054]FIG. 22 shows an exploded view of an interconnection similar to that of FIG. 20. A portion of vertical post 232 is shown with structural fitting 260 engaged to its side. The structural fittings may be oriented in various positions. However, for ease of description, the fitting 260 will be described in the orientation illustrated, with such terms as left and right being arbitrary. The fitting 260 has a base 262 at its left end and engagement members 264 at its right end. The base 262 has an end surface that is radiused so as to mate with the outer surface of the sheathing covering the vertical post 232. A bore, not shown, passes through the base 262. A bolt or screw 268 passes through this bore and engages the vertical post 232. The bolt or screw 268 may be self-threading, or may require that a hole be drilled and/or tapped in the post 232. The bolt 268 engages the hole in the post 232 and brings the radiused end surface 266 of the base 262 into firm contact with the side of the post 232. Engagement members 264 extend rightwardly out of the base 262. The engagement members 264 include a pair of engagement fingers 270 and 272. Each finger 270 and 272 has a semi-arcuate outer profile configured to engage the interior diameter of the lower rail 238. As illustrated, the rail 238 has an inner steel rail 274 and a polymerized sheathing 276 surrounding the rail 274. The steel rail 274 has an inner diameter. The fingers 270 and 272 engage this inner diameter. The fingers 270 and 272 may be tapered or shaped so as to be a press fit into the rail 274, or may slide easily thereinto. A bolt or screw 278 interconnects the lower rail 238 with the fingers 270 and 272. In one embodiment, a hole 280 is provided in the lower finger 270. The lower rail 238 is slid onto the fingers 270 and 272. A hole is then drilled through the combination of the rail 274 and sheathing 276 so that the screw 278 can engage the hole 280. Alternatively, the screw may be self-tapping and make its own hole in the sheathing 276, rail 274, and/or the finger 270. The holes may also be pre-drilled in the ends of the rail 238. For some applications, a screw or bolt may not be required to maintain assembly of the hand rail. A press fit may be sufficient or adhesives may be used to interconnect the rail to the fitting. As another alternative, the screw 278 may engage the hole 280 in the lower finger 270 and, when sufficiently tightened, press against the upper finger 272, thereby spreading the fingers 270 and 272 apart so as to securely engage the inner diameter of the rail 274. Referring again to both FIGS. 20 and 22, it can be seen that the base 262 of the fitting 260 has an outer diameter similar to the outer diameter of the sheath 276 of the rail 238 so that, when assembled, the fitting 260 and the lower rail 238 have flush outer diameters giving a very pleasing appearance.

[0055] Referring now to FIG. 21, a detailed view of an upper comer of the hand rail system of FIGS. 14-18 is shown. The upper end of one of the vertical posts 234 is shown interconnected with one end of the upper rail 236 using another slip-in structural fitting 290. The slip-in structural fitting 290 is the same as shown in FIG. 22, though the orientation has been changed. An end cap 292 is also provided that closes the open end of the upper rail 236 where it extends beyond the upper end of the vertical post 234 and the fitting 290.

[0056] Referring now to FIG. 23, alternative structural fitting 294 is shown. The fitting 294 is again a slip-in fitting, but is designed to form a corner without the need for the end cap 292 shown in FIG. 21. Instead, the fitting 294 has a first pair of fingers 296 extending in a first direction and a second set of fingers 298 extending in a second direction, with the second direction positioned at 90 degrees to the first direction. As will be clear to those of skill in the art, other slip-in structural fittings may be provided, such as T-shaped fittings, or fittings that support any number of structural members at any number of angles. As a further alternative, a T-shaped fitting may be provided with the leg of the T including slip-in fingers while the “top” of the T is a slip-on structural fitting. This combines the benefits of the slip-on and slip-in fittings. It gives a flush appearance between the fitting and a member that extends in one direction, but allows adjustment where the “top” of the T engages another member. Any of these slip-in fittings may be used in any embodiments of the present invention.

[0057] According to a further aspect of the present invention, a hand rail, a guard rail, or a rail system with an infill panel, such as previously described, may be coated with a plastic coating instead of using individual pieces of plastic sheathing. Referring again to FIG. 1, a hand rail system may be constructed with a pair of spaced apart upright or vertical members with one or more horizontal members extending therebetween. The various members may be assembled using slip-in or slip-on structural fittings, as previously described. However, the hand rail will be assembled without plastic sheathing covering the individual members. Instead, it would be constructed of steel tubing with the structural fittings. Once assembled, the entire assembly is coated with a plastic coating such as spray-on polyurea. The polyurea coats the members and the fittings so as to entirely seal in all portions of the hand rail system. The coating may be added in the field after the members and fittings are assembled. Alternatively, the members and fitting may be preassembled and precoated with the final assembly shipped as a precoated piece and installed in place. A base support, such as 56 in FIG. 1, may be provided, and coated along with the rest of the members. Alternatively, the generally vertical members may be inserted into holes in the ground or floor. The portion of the vertical members that is to be placed into a hole may be precoated, or the coating may be left off of a portion of the members. The plastic coating provides a protective coating, seals the assembly, improves the aesthetic appearance, reduce maintenance, and provides a unique appearance.

[0058] According to another embodiment of the present invention, hand rails with infill panels such as shown in FIGS. 5-18 may be assembled without polymerized sheathing, using either slip-on or slip-in structural fittings, and then coated with a plastic coating. In one embodiment, the infill panel is also coated. For example, a metal mesh infill panel may be provided with a plastic coating covering the mesh. Alternatively, the infill panel may be added after coating the remainder of the hand rail, or coated separately.

[0059] The spray-on coating may be used with any embodiment previously discussed in the present specification. In each case, the plastic sheathing is preferably left out of the assembly. The structural fittings are locked into place using the set screws or other fasteners, and then the entire assembly is coated, preferably by spray coating with a polyurea. The coating seals the fittings to the members, thereby additionally securing them in place. Additionally, the coating covers fasteners to prevent accidental backing out, and to discourage vandalism. Spray coating according to the present invention may also be used with other configurations of guard rails and hand rails. For example, various designs for guard rails and hand rails are shown Applicant's U.S. Pat. Nos. 5,566,927; 5,624,103; and 6,131,886, all of which are incorporated in their entirety herein by reference. In each case, the various members may be assembled without a plastic sheathing and then coated with a plastic coating, preferably by spray-on polyurea.

[0060] As yet another alternative, the various components of any of the guard rails or hand rails may be coated prior to assembly. In one example, each of the elongated vertical or horizontal members is coated with a plastic coating and allowed to dry. The precoated members are then assembled to one another using slip-in or slip-on structural fittings.

[0061] The above description is considered that of the preferred embodiment only. Modifications of the invention may occur to those of ordinary skill in the art. Therefore, it is understood that the embodiments shown in the drawing and described above are merely for illustration purposes and are not intended to limit the scope of the invention. 

1. A hand rail system comprising: at least two spaced apart vertical rails having upper and lower ends; at least two spaced apart horizontal rails engaged with said vertical rails and positioned above said lower ends of said vertical rails; a plurality of slip-on structural fittings for engaging said horizontal rails with said vertical rails, each fitting having a securing mechanism that secures said rails to said fitting; and a plastic coating covering and sealing the vertical and horizontal rails and the structural fittings.
 2. The hand rail system as defined in claim 1, wherein at least one of the fittings comprises a T-shaped member having a hollow interior, each leg of the T-shaped member having an interior matching the exterior profile of the horizontal rails and the vertical rails, the interior profile having a diameter equal to or greater than the exterior diameter of the rails.
 3. The hand rail system as defined in claim 1, wherein at least one of the fittings comprises an L-shaped member having a hollow interior, each leg of the L-shaped member having an interior profile matching the exterior profile of the horizontal rails and the vertical rails, the interior profile having a diameter equal to or greater than the exterior diameter of the rails.
 4. The hand rail system as defined in claim 1, further comprising: a third vertical rail, the horizontal rails being engaged with the third vertical rail; and the plastic coating covering the third vertical rail.
 5. The hand rail system as defined in claim 1, wherein the spaced-apart vertical rails and the spaced-apart horizontal rails define a framed area, the system further including an infill panel having an area which substantially consumes the framed area; the panel being mounted in the framed area, and the plastic coating covering and sealing the infill panel.
 6. The hand rail system as defined in claim 5, further comprising one or more sections of U-channel affixed to each of the vertical rails and the horizontal rails for mounting the infill panel.
 7. The hand rail system as defined in claim 5, wherein the infill panel is a mesh screen.
 8. The hand rail system as defined in claim 5, wherein the infill panel is a solid panel.
 9. The hand rail system as defined in claim 1, wherein the plastic coating is a spray on polyurea.
 10. A hand rail assembly comprising: a perimeter frame composed of steel tubing covered with plastic sheathing, the perimeter frame surrounding a framed area; an infill panel disposed in the framed area such that the panel is surrounded by the perimeter frame; and a plastic coating covering and sealing the perimeter frame and the infill panel.
 11. A hand rail assembly comprising: a pair of spaced apart vertical posts each having a lower end and an upper end, the lower ends being configured to engage a support surface; an upper rail extending between the upper ends of the vertical posts; a lower rail extending between the vertical posts and positioned below the upper rail; the vertical posts and the rails together defining a perimeter frame having a framed area defined therein, the framed area having a top edge defined by the upper rail, a lower edge defined by the lower rail, and sides defined by the vertical members; an infill panel supported in the framed area; and a plastic coating covering the posts and rails and infill panel.
 12. The hand rail assembly according to claim 11, further comprising structural fittings interconnecting the rails with the posts, at least one of the structural fittings comprising a slip-in fitting having a base with a radiused end surface matching the outer diameter of one of the posts or rails, the fitting further having an engagement member extending from the base, the engagement member configured to engage the inner diameter of one of the posts or rails.
 13. The hand rail assembly according to claim 12, wherein the structural fitting further comprises a connector operable to connect the fitting to one of the posts or rails such that the end surface mates with the outer diameter of the post or rail.
 14. The hand rail assembly according to claim 12, wherein the base of the structural fitting has an outer diameter substantially the same as the outer diameter of the rails.
 15. The hand rail system according to claim 12, wherein the engagement member comprises a pair of engagement fingers shaped to fit into the inner diameter of the post or rail.
 16. The hand rail assembly according to claim 11, further comprising structural fittings interconnecting the rails with the posts, at least one of the structural fittings comprising a slip-on fitting having an inner diameter greater than or equal to the outer diameter of the posts or rails.
 17. A hand rail assembly with an infill panel, comprising: a pair of spaced apart vertical posts each having a lower end and an upper end, the lower ends being configured to engage a support surface; an upper rail extending between the upper ends of the vertical posts and engaged to the upper ends of the vertical posts; a lower rail extending between the vertical posts and positioned below the upper rail, the lower rail engaged to the vertical posts; the vertical posts and the rails together defining a perimeter frame having a framed area defined therein, the framed area having a top edge defined by the upper rail, a lower edge defined by the lower rail, and sides defined by the vertical posts; an infill panel supported in the framed area; and a spray on polyurea coating covering the posts and rails and infill panel.
 18. The hand rail assembly according to claim 17, further comprising structural fittings interconnecting the rails with the posts, at least one of the structural fittings comprising a slip-in fitting having a base with a radiused end surface matching the outer diameter of one of the posts or rails, the fitting further having an engagement member extending from the base, the engagement member configured to engage the inner diameter of one of the posts or rails, the polyurea coating covering the fittings along with the posts and rails so as to seal the fittings to the posts and rails.
 19. The hand rail assembly according to claim 18, wherein the structural fitting further comprises a connector operable to connect the fitting to a post or rail such that the end surface mates with the outer diameter of the post or rail.
 20. The hand rail assembly according to claim 18, wherein the base of the structural fitting has an outer diameter substantially the same as the outer diameter of the rails.
 21. The hand rail system according to claim 18, wherein the engagement member comprises a pair of engagement fingers shaped to fit into the inner diameter of the post or rail. 